REMEHA GAS 460 S Owner's manual

Remeha Gas 460 S
Gas-fired boilers
Technical
instructions
English
06/02/06

Contents
Remeha Gas 460 S 06/02/06 - 300005247-001-B
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3 Main parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4 Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5 Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1 Furnace operation equipped with safety box RV 00 54 / 000 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Adapting to another gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2 Changing the ignition burner injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3 Changing the burner injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4 Setting the injector pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5 Checking the minimum gas pressure switch setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6 Attaching the label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Commissionning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1 Pressure settings and calibrated injector markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2 Final checks before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1 Checking and cleaning the main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Spare parts Gas 460 S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

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06/02/06 - 300005247-001-B Remeha Gas 460 S
Introduction
This product will be marketed in the following European Union
member states:
GB - HU - ES
Directive 97/23/EC
Gas and oil boilers with a maximum operating temperature of 110°C
and hot water tanks with a maximum operating pressure of 10 bar
pertain to article 3.3 of the directive, and therefore, cannot be CE-
marked to certify compliance with the directive 97/23 EC.
The boilers and hot water tanks are designed and manufactured in
accordance with the sound engineering practice, as requested in
article 3.3 of the directive 97/23/EC; it is certified by compliance with
the directives 90/396/EC, 92/42/EC, 73/23 EC and 89/336/EC.
1 Regulations
It is in any case imperative to conform to the local
regulations in force. We would draw your attention to the danger of corrosion in boilers located in or close to premises in which the atmosphere
may be polluted by chloride or fluoride compounds.
For example: Hairdressing salons, industrial premises
(solvents), refrigeration units.
In this event, we cannot uphold the warranty.
2 Symbols used
Caution danger Risk of injury and damage to equipment. Attention must be paid to the warnings on
safety of persons and equipment
Specific information Information must be kept in mind to maintain comfort
ZReference Refer to another manual or other pages in this instruction manual

4Remeha Gas 460 S 06/02/06 - 300005247-001-B
Description
1Introduction
Gas 460 S boilers are made of cast iron:
- with atmospheric gas burners
- with 2 operating stages
- with electronic ignition via the ignition burner for hot water central
heating
- with a useful output of between 119 and 380 kW
They are designed to be connected to a chimney.
The figure given after Gas 460 S indicates the number of sections
which make up the boiler.
Gas 460 S boilers are delivered with a K control panel. They can be
fitted with an optional RC4 and RC5 control unit (master-slave control
unit options).
2 Certifications
2.1 Introduction
It is CE approved under the following number : 0085BL0187
The boilers are in compliance with the EC directives:
- Royal Decree dated 8th January 2004
- 90/396/EEC Gas Appliance Directive
- 73/23/EEC Low Voltage Directive
Reference Standard : EN 60.335.1
- 89/336/EEC Electromagnetic Compatibility Directive
Reference Standard : EN 50.081.1 ; EN 50.082.1 ; EN 55.014
- 92/42/EEC Efficiency Directive ** 1,
Low temperature gas boiler
- Type B11 (B11BS if fitted with the optional combustion products
discharge control system).
France:
Performance class III boiler according to ATG B 84
recommendations.
Belgium:
The boilers comply with the specifications of the HR+ quality label.
The boilers should be fitted with a 160 VA circuit separation
transformer (delivered with the documentation package).
2.2 User country
The boilers leave the factory operating with H natural gas.
User country ES HU GB
Category II2H3P II2H3P II2H3P
Gas type G20G31G20G31G20
Distribution pressure (mbar) 20 37 25 50 20

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06/02/06 - 300005247-001-B Remeha Gas 460 S
3Mainparts
3.1 Boiler
1 Control panel
2 Safety box
The safety control box is fitted to the control panel and controls the
burner ignition, function and extinction sequences.
3 Multivalve gas unit:
It includes a safety valve and a 2-stage principal valve with filter and
minimum gas pressure switch.
4 Ignition burner valve
5 Ignition burner
6 Flame inspection window
7 Ionisation probe: It detects flame presence on the ignition burner by
flame ionisation.
8 Ignition electrode: This ensures ignition burner ignition using a high
voltage spark.
9 Minimum gas pressure switch
(Minimum pressure: 12.5 mbar)
10 Ignition box

6Remeha Gas 460 S 06/02/06 - 300005247-001-B
3.2 Control panel
13-position switch Auto / Manual !/ TEST STB
- The switch may be left on either position manual !or automatic AUTO.
-STB TEST: Temporary action to test the safety thermostat.
- Press the TEST STB switch and set pump shut-off switch (2) 9to the “Summer” position %.
2 Switch Burner / Heating pump:
This button is used to control the burner and the heating pump.
Both buttons are in “Winter” .position: Heating and hot water production systems operate (if a hot water tank is included).
Both buttons are in “Summer” %position: The burner and the heating pump don't operate.
If the boiler is fitted with a control unit, both buttons must be left on the Winter .position.
3 Main ON/OFF switch
4 Location for hour run meter for the first and second stage (optional)
5 Boiler thermostat (30 to 90 °C):
A factory-set stop limits the maximum temperature to 75 °C. The stop may be moved if necessary.
6 Stage one or stage two indicators:
These only go on if the relevant thermostat or control unit require heating and if the safety contact is closed.
7 Boiler thermometer
8 Location for flue gas thermometer (optional)
9 Safety thermostat with manual reset (set to 110 °C).
10 10 A Circuit-breaker: with delayed action and manual reset.
11 Location for optional features or a RC4/RC5 control unit
13 Switch for selecting the number of burner stages
14 Burner alarm indicator + Reset button

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06/02/06 - 300005247-001-B Remeha Gas 460 S
4 Technical characteristics
The boilers can operate on natural gases type H/L.
(1) at 2nd stage
1 mbar = 10 mmCE = 10 daPa = 100 Pa
Boiler Gas 460 S / 810 12 14 16 18 20
Useful efficiency 1st stage kW 83-98 107-126 131-154 155-182 179-210 202-238 226-266
2nd stage kW 119-140 153-180 187-220 221-260 255-300 289-340 323-380
Power input
1st stage kW 93.1-
108.9
119.4-
139.7
145.6-
170.4
171.9-
201.1
197.9-
231.5 224-262.1 250.1- 292.6
2nd stage kW 131.1-153 168.2-
196.3
205.2-
239.4
242.2-
282.6
278.8-
325.4
315.7-
368.4
352.4-
411.3
Numberofsections Part 8 101214161820
Mass flue gas flow rate (1) kg per
sec 0.097 0.127 0.144 0.177 0.191 0.203 0.258
Flue gas temperature Tf
Boiler temperature 80°C °C 125 123 130 126 133 140 126
CO2
1st stage %3.9-4.9 3.8-4.8 4.3-5.3 4.0-5.0 4.5-5.5 5.0-6.0 4.0-5.0
2nd stage 5.4-6.4 5.3-6.3 5.8-6.8 5.5-6.5 6.0-7.0 6.5-7.5 5.5-6.5
Ionisation current µA 1.0
Required depressurisation at the
nozzle daPa 0.7
Minimum outlet temperature °C 40
Maximum outlet temperature °C 90
Maximum operating pressure bar 6
Electrical connection V/Hz 230/50
Electrical output W 108 / 114 maximum
Gas connection 20 mbar inch 1" 1" 1" 1"1/4 1"1/4 1"1/4 1"1/2
Heating connection inch 2"
Internal diameter flue gas nozzle mm 250 300 300 350 350 350 400
Water resistance (1)
∆T = 10K
mbar
80 133 198 277 369 484 592
∆T = 15K 36 59 88 123 164 211 263
∆T = 20K 20 33 50 69 92 118 148
Water capacity* l 61 76 91 106 122 137 154
Shipping weight kg 668 807 934 1096 1227 1364 1476

8Remeha Gas 460 S 06/02/06 - 300005247-001-B
5 Main dimensions
Heating outlet R 2
Heating return R 2
Draining Rp 3/4
1406
B
H
= =
ø C
D
64
G
J
410
375
130
A
1006
130
E
60
ø F
8358N061A
1
2
3
Boiler Gas 460 S /8 /10 /12 /14 /16 /18 /20
A (mm) 1362 1362 1362 1412 1412 1412 1462
B (mm) 970 1146 1322 1498 1674 1850 2026
Ø C (mm) 250 300 300 350 350 350 400
D (mm) 632 808 984 1160 1336 1512 1688
E (mm) 165 165 165 190 190 190 220
Ø F (mm) (20/25 mbar) Rp1 Rp1 Rp1 Rp1 1/4 Rp 1 1/4 Rp 1 1/4 Rp 1 1/2
Ø F (mm) (300 mbar) Rp 3/4
G447 535 623 704 792 880 963
H445 445 445 454 454 454 507
J1094 1094 1094 1194 1194 1194 1194

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06/02/06 - 300005247-001-B Remeha Gas 460 S
Operation
1 Furnace operation equipped with safety box RV 00 54 / 000 00
Operating principle
The boiler can operate at either 2nd stage or 1st stage depending on
the thermal needs of the installation.
The ignition and burner surveillance sequences are ensured by the
safety box.
Behaviour in normal conditions
The box closes the TCH contact when there is a requirement for
heat1. The safety control box runs an auto-check of around 1
second(s) by lighting the alarm warning light VA.
In the case of an offset alarm, it is necessary to use a timed
relay in order to prevent an unjustified alarm signal.
After a waiting time tw, the ignition transformer TA produces a series
of sparks at the ignition electrode. After a pre-ignition period tvz, the
ignition burner valve VG and the safety valve VS open. Formation of
flame in ignition burner. The ionisation sensor SF shows a flame
signal with a minimum ionisation current of 1 µA and ignition is shut
down. After a period of stabilisation tstab, the principal burner ignites
at 1st stage BR1 (or at 2nd stage if the 2nd stage thermostat TCH2
is needed).
Behaviour in abnormal conditions
- If a flame is not detected before the safety time ts, the box makes
2 more ignition attempts. If, at the end of the last attempt, there is
still no flame signal, the box goes into safety and the safety
indicator comes on. To restart the heater, press the reset button on
the safety box.
- If there is a loss of flame in normal operation, the box automatically
repeats the start up sequence.
Resetting
The box is reset after going into safety by pressing the reset button.
If the reset button does not work, wait at least 15 seconds before
trying a second time. After activating the reset button, the warning
light goes out and the safety control box restarts after a waiting time
of around 1 minute.
Note 1: The box may be on safety on its first start up: press the reset
button to release it.
Note 2: If the reset button is pressed in normal operation, the gas
valves close and the box starts a new ignition sequence.

10 Remeha Gas 460 S 06/02/06 - 300005247-001-B
Required input signals
Box output signals
Thermostatic request at 2nd stage
Operation 2nd stage
AStart of operation
BFormation of flame in ignition burner
BR1 1st stage
BR2 2nd stage
SF Burner flame signal
TA Ignition transformer
TCH1 Boiler thermostat 1 Speed
TCH2 Boiler thermostat 2 Speed
VA Safety lockout warning light
VG Ignition burner valve + Safety valve VS
ts Safety time: maximum 10 seconds
tstab Flame stabilisation time: 5 seconds
tvz Pre-ignition time: 10 seconds
tw Waiting time: 0 seconds
8358N016A
Normal operating cycle
Operating cycle on safety (start up without flame signal)

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06/02/06 - 300005247-001-B Remeha Gas 460 S
Adapting to another gas
These actions must be carried out by a qualified
technician. Belgium: The operations required to switch from one gas to another must be carried out by a SERV'elite technician.
1 Changing gas
The boilers are factory-set to operate on natural gas H (G20 - 20
mbar). To convert it to natural gas L, use the gas L conversion kit
(optional). Carry out the operations described below.
2 Changing the ignition burner injector
Operations to be carried out to convert from natural gas H to natural
gas L and vice versa:
Remove the gas supply pipe from the ignition burner (13 mm
spanner).
Remove the nozzle + seal.
Unscrew the nozzle using a screwdriver and screw in the new
injector.
- Reassemble the parts
- Carry out a leak tightness check
Natural gas H Natural gas L
Nozzle marking 80 100
Nozzle diameter 0.80 mm 1.00 mm

12 Remeha Gas 460 S 06/02/06 - 300005247-001-B
3 Changing the burner injectors
- Close the gas valve.
- Lift out the injector with a number 12 spanner assemble the new
injectors with their new joint.
First tighten the injectors by hand and carefully lock them using
a spanner.
- Carry out a leak tightness check.
Natural gas H Natural gas L
Nozzle marking 390A 450A
Nozzle diameter 3.9 mm 4.5 mm

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06/02/06 - 300005247-001-B Remeha Gas 460 S
4 Setting the injector pressure
Setting the pressure 2nd stage
The pressure must be set by a qualified professional.
The boiler must be commissioned after having checked the points
covered in this chapter: Final checks before commissioning.
- Connect a manometer to the pressure outlet.
- Run the boiler at 2nd stage, activating the thermostat(s).
- Set the pressure at the injectors as follows:
- Free the cylindrical split head screw C by around one turn. Fully
unscrew the setting button
D (anti-clockwise). Tighten the screw
C .
- Set the pressure at the injectors by turning the screw on the
regulator
B . By turning to the right, you increase and, by turning to
the left, you decrease the principal flow.
If you find you cannot tighten screw Bany further before
reaching the desired pressure, unscrew Bagain by a quarter
turn and continue the setting by turning Dafter freeing the
inhibitor screw C.
- On propane, the regulator Bis fully tightened. It is not used.

14 Remeha Gas 460 S 06/02/06 - 300005247-001-B
Setting the pressure 1st stage
- Run the boiler at 1st stage by activating the burner on selector
switch on the boiler control panel.
- Set the flow in such a way as to obtain pressure at the injectors (0.5
x Pressure 2nd stage):
- Set the 1st stage flow with the ring E .
- By turning to the right, you increase and, by turning to the left, you
decrease the principal flow.
- Tighten the inhibitor screw
C .

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06/02/06 - 300005247-001-B Remeha Gas 460 S
Setting the start-up progressivity (or initial flow)
In the factory, the progressivity is set to minimum (low start-up
pressure).
Depending on the installation conditions, adjust the progressivity
setting in order to guarantee optimum boiler start-up.
- Unscrew the protection cap G. Use like a spanner to turn the
setting rod Huntil you obtain the desired initial flow.
- Put the cap back in place.
5 Checking the minimum gas pressure switch setting
The minimum gas pressure switch on the safety valve is set in the
factory to a value of 12.5 mbar, which corresponds to the setting for
natural gas.
To operate on propane, set the start-up pressure to 20 mbar.

16 Remeha Gas 460 S 06/02/06 - 300005247-001-B
If there is a drop in the gas supply pressure, the minimum pressure
switch shuts down the boiler.
6 Attaching the label
Affix the label which indicates for which type of gas the boiler is fitted
and set.

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06/02/06 - 300005247-001-B Remeha Gas 460 S
Commissionning
1 Pressure settings and calibrated injector markings
1.1 Table of pressure settings and injector markings + Flow table (15°C - 1013 mbar)
Boiler type Gas 460 S / 810 12 14 16 18 20
Useful efficiency
1st stage kW 83-98 107-126 131-154 155-182 179-210 202-238 226-266
2nd stage kW 140 180 220 260 300 340 380
Power input
1st stage kW 93.1-108.9 119.4-139.7 145.6-170.4 171.9-201.1 197.9-231.5 224-262.1 250.1-292.6
2nd stage kW 131.1-153 168.2-196.3 205.-239.4 242.2-282.6 278.8-325.4 315.7-368.4 352.4-411.3
Nozzle
Diameter, principal burner injector
Gas H mm 3.9
Diameter, principal burner injector
Gas L mm 4.5
Diameter, ignition
burner injector
Gas H mm 0.8
Gas L mm 1.0
Gas flow rate
Gas H 1st stage m3/h 9.35-11.52 12.63-14.78 15.41-18.03 18.19-21.28 20.94-24.50 23.71-27.74 26.47-30.97
2nd stage 13.88-16.19 17.80-20.77 21.71-25.33 25.63-29.91 29.51-34.43 33.40-38.98 37.29-43.52
Gas L 1st stage m3/h 11.46-13.40 14.70-17.19 17.92-20.97 21.16-24.75 24.36-28.50 27.57-32.26 30.78-36.02
2nd stage 16.14-18.83 20.70-24.16 25.25-29.46 29.81-37.78 34.32-40.05 38.85-45.34 43.38-50.62
Downstream gas pressure
Gas H 1st stage mmCE Pressure 1st stage = 0.5 x 2nd stage pressure set
2nd stage 90-120
Gas L 1st stage mmCE Pressure 1st stage = 0.5 x 2nd stage pressure set
2nd stage 74-100

18 Remeha Gas 460 S 06/02/06 - 300005247-001-B
2 Final checks before commissioning
The first start-up is to be performed by your installation
engineer.
Make the gas line setting before commissioning.
Check the following points before starting the heater:
Hydraulic circuit:
`Check that the installation and boiler are adequately filled with
water and correctly irrigated and bled.
`Check that the hydraulic connections are leak tight.
Gas circuit:
`Check the adjustment of the gas line:
- Connect a manometer to the pressure socket located on the
manifold.
- Check that the nozzle pressure and the start-up pressure match
the pressures given in the relevant chapter: Pressure settings and
calibrated injector markings.
If necessary, adjust the pressure as shown in the relevant
chapters: Setting the injector pressure.
Electrical connectors:
Check that the connectors under the control panel are correctly fitted:
1Ignition circuit
2Gas pressostat
3Gas valve circuit
4Leak proofing system (Options RE 30)

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06/02/06 - 300005247-001-B Remeha Gas 460 S
Maintenance
1 Checking and cleaning the main components
1.1 Cleaning heater body
The extent of clogging on the heating body must be checked once a
year.
If it is necessary to sweep the boiler, remove the burner drawer to
prevent deposits and soot blocking the orifices in the gas trains.
With the burner out:
- Remove the upper casing of the boiler
- Take out the insulation
- Remove the sweeping hatch from the draught diverter
- If necessary, clean the boiler body using the special brush
provided
- Clean the combustion chamber using a vacuum cleaner
835 022
8N

20 Remeha Gas 460 S 06/02/06 - 300005247-001-B
1.2 Cleaning main burner and ignition burner
The main burner and the ignition burner injector with its filter must be
regularly cleaned to ensure good performance. We recommend
doing this at least once a year.
These actions must be carried out by a qualified
technician.
Main burner
- Switch off the boiler electrical power supply
- Cut the gas supply
- Clean the burner trains (slits) using a soft brush, a short-handled
brush or a vacuum cleaner.
Ignition burner
Do not use a metal brush.
8358N064A
7
1
8
9
3
4
5
2
13
11
12
13
10
6
1Remove the lower cladding panel
2Remove the intermediate cladding panel
3Disconnect the valve connector
4Disconnect the gas pressure switch connector (and the leak proofing
cyclical control system, if there is one) under the control panel
5Disconnect the ignition circuit
6Disconnect the ionisation cable and the ground conductor on the
ionisation sensor side
7Unscrew the union joint on the gas inlet pipe
8Unscrew the 4 holding nuts on the burner drawer
9Take out the burner drawer
10 Remove the gas supply pipe from the ignition burner (13 mm
spanner)
11 Clean the injector
12 Clean the ignition burner
13 Clean the flame stabilisation pipe located inside the ignition burner